ENERGY USE IN THE STEEL INDUSTRY. Rizwan Janjua Manager, Technology and Environment

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1 ENERGY USE IN THE STEEL INDUSTRY Rizwan Janjua Manager, Technology and Environment

2 Overview Global Steel Industry Overview Energy use in the steel industry - aims, goals & status - methodology & web based tool - analysis results 3

3 The iron and steel industry where are we Total world crude steel production in 2013: Mt Energy costs represent around 20 to 25 % of the total input of steel producers and is one of the most important items to manage by steel producers Coking coal accounts for more than 65% of primary source of energy Average Energy Intensity: BF-BOF GJ / t CS, Average CO 2 Intensity: 1.77 t CO 2 / t CS Operational production proportion BF / BOF: 69.6% EAF: 29.3 % OHF: 1.1% 4

4 Energy use in the steel industry 5

5 Project objectives and background Enable steel producers to: Make a fair comparison of their own energy consumption with a standard reference plant and with their peers on a site and facility basis Identify the performance gap between their own performance, the reference and peers on a site and facility level Monitor their trend of improvement of their energy performance taking into account all key factors, e.g. process production level, raw material selection, technologies etc. Provide a online web based tool for the worldsteel members to measure their performance on an annual or ad-hoc basis. Evaluate technologies and forecast potential improvements based on practical performance levels. 9

6 The study covers these facilities or plant types Sintering Pelletizing Direct Reduced Iron Coking Iron making (BF) BOF EAF Continuous Casting Hot Rolling Mill Air Separation Unit Power Plant Flares GJ / t of Crude Steel / Cast Steel or process Product or / and GJ / t of HR Coil 10

7 Energy Data Collection System (V2) 47 energy surveys already uploaded to the EDCS - Database developed in 4 languages - Standard safety data store - Multilevel data entry (administrator and user entry) - 1 system used for 4 worldsteel projects (Safety, Energy, CO 2 data collection and Maintenance & Reliability) - Allow to entry for more users at the same time 11

8 Gap analysis within the energy use project GAP Performance gap vs. reference Raw Material Selection Impact Improvement potential Operation & Technology gap Energy Efficient Technology impact Continuous Improvement potential Web Tool Final Report

9 Principle of performance assessment for multi-step production routes Reference Compared Facility Steel making Steel making Iron making Iron making Coke making Coke making Bonus Penalty

10 Example of an energy intensity analysis for a sinter plant Top 25% The project team decided to set the reference at the top 25% of performance of the plants.

11 Roll up Methodology of energy intensity assessment 1 Roll-up Primary Metal level Sinter Plant + Coke Oven Plant BF Plant 2 Roll-up Crude Steel level (1 + Steel Shop) 3 Roll-up Hot Rolled level (2 + Hot Rolling Mill) 4 Roll-up site level (3 + Power Plant + ASU + Flares) 16

12 Coke oven plants energy intensity comparison with worldsteel reference % 80.00% 80.74% 60.00% 40.00% 20.00% 0.00% % % % -3.04% 0.18% 1.90% 3.64% 55.49% 47.33% 41.47% 28.10% 30.87% 33.95% 34.58% 19.37% % % % % % JTBM001 PAGO001 QTOL001 PDMS002 JFUH001 YLOM006 QEIU173 RDHE001 QRDT003 QRDT004 TLKB001 QWCE001 QRDT001 JEVS003 PDMS001 MOPE658 YBXN001 Offset to reference [%] Sites 17

13 Analyzed site waterfall graph 18

14 BF plant process waterfall graph 19

15 Energy intensity saving potential from participating plants BF-BOF EAF (100% scrap) Energy intensity Energy saving potential Energy intensity Energy saving potential Max intensity Max intensity 8.66 Average value 18.7 Average value 6.74 Reference value GJ/t (5%) Reference value 6.74 Best performer GJ/t (15%) Best performer GJ/t (20%) GJ/t CS GJ/t CS 21

16 Thank you for your attention, Questions????. For further information contact: Dr Rizwan Janjua Manager, Technology & Environment World Steel Association T: Mob: worldsteel.org Chih-Cheng Wu Manager Technology and Environment World Steel Association T: +32 (0) worldsteel.org 22

17 worldsteel.org